2.4.1. Removal and installation of the oil pallet

Fig. 2.183. Components of the oil pallet and module of the balancer shaft: 1 – bolt of 15 N · m; 2 – masloizmeritelny probe; 3 – zapolnitelny funnel; 4 – the directing tube; 5 – pro-rate; 6 – the module of balancer shafts with the oil pump; 7 – · m + to tighten a bolt of 15 N on 1/4 about. (90 °); 8 – bolt of 15 N · m; 9 – oil pallet; 10 – bolt of 15 N · m; 11 – sealing cuff; 12 – an opening bolt for discharge of oil, 30 N · m; 13 – asterisk; 14 – bolt of 10 N · m; 15 – protective cap; 16 – sensor of level and temperature of oil; 17 – sealing cuff; 18 – bolt of 20 N · m +90 °; 19 – chain cover; 20 – chain; 21 – sealing flange



NOTE
If at repair of the engine in engine oil metal shaving and dust in large numbers is found – a source of which is the increased wear, for example, because of damage of conrod or radical bearings, – that to avoid the subsequent damages, it is necessary to replace, besides cleaning of lubricant channels, the oil heater.

NOTE
The engine at manufacturer is filled with engine oil of the VW 503 00 standard. This engine oil is calculated on long intervals of maintenance (WIV). It is possible to use also listed below engine oils.

Engine oils according to the VW 500 00, 501 00 standard or 502 00 can be used and further. Oil is necessary заменяйть every 12 months or each 15.000 km, and it is necessary to program the indicator of frequency of service as appropriate.

Removal

Fig. 2.54. Engine casing


Remove a casing of the engine (fig. 2.54).

NOTE
At installation install all fasteners of cables removed or which are cut off during dismantling on former places again.

Separate a rubber sealant from the edges of a wing connected by bolts.

Fig. 2.184. Making of laying on both parties between the edge of a wing connected by bolts and the vertical leaf lying under it


Not to damage edge of a wing of traversy, lay linings on both parties between the edge of a wing connected by bolts and the vertical leaf (fig. 2.184) lying under it.
Establish to a traverse with adapters 10222/3 on edge of a wing

Fig. 2.185. Installation traverses with adapters


Pick up running screws to engine eyes, as shown in the figure 2.185.
Slightly tighten the engine by means of running screws.
Take off poliklinovy a belt.

Fig. 2.44. Bolts of an exhaust pipe of an independent additional heater


In cars with an additional heater unscrew bolts of an exhaust pipe of an independent additional heater from the noise-insulating screen (fig. 2.44).

Fig. 2.45. Fastening of a forward noise isolation


Weaken quick disconnect couplings 1 and 2 and remove a forward noise isolation (fig. 2.45).
Where are available, weaken quick disconnect couplings 3 and remove the back noise-insulating screen.
Install the device for pumping of oil under the engine and merge engine oil.

Fig. 2.186. Fastenings of an emphasis and return oil pipeline


Turn off bolts and remove an emphasis against a provorachivaniye from the oil pallet (fig. 2.186).
Turn off the return oil pipeline 1 from a turbocharger on the oil pallet.

Fig. 2.65. Electric socket of the sensor of level and temperature of oil


Disconnect the electric socket from the sensor of level and temperature of oil (fig. 2.65).

Fig. 2.66. Air conditioning system contour tube arm


Remove air conditioning system contour tube arm from the oil pallet (fig. 2.66).

Fig. 2.67. Fastening of the compressor of the conditioner and shtekerny socket of a wire


Disconnect the electric socket of 1 wire of the electromagnetic coupling of the compressor of the conditioner (fig. 2.67).

ATTENTION
It is forbidden to open a contour of air conditioning system of climatic installation.

Turn off the conditioner compressor from an arm.

NOTE
To avoid damages of the condenser, and also pipelines and hoses of a contour of air conditioning system, it is necessary to watch that lines and hoses were laid without tightness, excesses and breaks.

Suspend the conditioner compressor with the connected lines from below on the car.

Fig. 2.187. Electric socket of the forward left sensor of clearance


Disconnect the electric socket from the forward left sensor of clearance (fig. 2.187).

Fig. 2.188. Fastening of support of the stabilizer


Turn off fastening of support of the stabilizer 1 and 2 (fig. 2.188).
Prop up a stretcher the service crane.

Fig. 2.189. Holders of a wire of a starter


Cut cable couplers, open the holder of a wire of a starter, take a wire (fig. 2.189).
Turn off a nut 3 from below on an engine support.
Turn off bolts 4 and 5 on the engine support console.

Fig. 2.190. Fastening of a support of the engine


Turn off a bolt 1 in front on a stretcher and remove the console of support of the engine 2 (fig. 2.190).
Repeat these operations on the opposite side of the car.
Slowly lower a stretcher by means of the crane.
Pull the engine by means of running screws of device for posting a little up, at the same time you watch freedom of the course of drafts and control levers the mechanism of gear shifting and system of release of OG.

Fig. 2.191. Bolts of fastening of KP and oil pallet


Unscrew bolts a box of transfers / the oil pallet (fig. 2.191).
Unscrew M10 bolts.
Weaken cross-wise bolts 1–18.

Fig. 2.192. Bolts of fastening of the oil pallet


Remove the oil pallet, if necessary dismantle, easily tapping with the rubber hammer (fig. 2.192).

Installation
Establish in the return sequence, at the same time it is necessary consider the following.

NOTE
Replace a sealing cuff.
For fastening of all connections of hoses use collars of the corresponding series.
At the return Ustanovkaye establish all cable couplers where they were established initially.

Remove the sealant remains on the oil pallet and the block of cylinders, for example, by means of the rotating plastic brush.
Clear landing surfaces; on them there should not be an oil and lubricant.
Cut off a tube nose on a forward mark (diameter of an opening about 2 mm).

Fig. 2.193. The scheme of putting sealant on the landing surface of the oil pallet


Apply sealant on the pure landing surface of the oil pallet, as shown in the figure 2.193.
Sealant plait thickness: 2–3 mm.

NOTE
The plait of sealant has to be not thicker than 3 mm, otherwise excess sealant can get to the oil pallet and litter the mesh filter in a maslozaborny branch pipe.

In the field of a back sealing flange it is necessary to apply sealant especially carefully.
The oil pallet has to be installed during 5 minposl of putting sealant.
At once put the oil pallet and twirl fastening bolts in the given sequence (fig. 2.192):
1. Bolts 1–18 tighten for the preliminary moment of an inhaling 5 N · m, alternating a cross on a cross.
2. Tighten bolts of the oil pallet / transmission with the moment of 45 N · m.
3. Tighten M10 bolts the moment of 40 N · m.
4. Tighten bolts 1–18 cross on a cross with the moment of 15 N · m.

Fig. 2.194. Size of a vystupaniye of the oil pallet



NOTE
At installation of the oil pallet 3 pay attention that the oil pallet has to stand aflush to an intermediate guard 1 to the removed engine, i.e. the pallet has to support the block of cylinders 2 on the A=0,8 size of mm (fig. 2.194).

After installation of the oil pallet let's dry to sealant about 30 min. Only after that it is possible to fill in engine oil.
Establish a stretcher.
Install the stabilizer.
Install the conditioner compressor.
Establish a poliklinovy belt.
Fill in engine oil and check its level.
Further installation and assembly is carried out in the return to sequence removal.